Quality Data Entry with Paper Forms and Scanning

There doesnt exist any other economical alternative to enter quality data than paper and scanning.
Typical applications are inspection charts filled out by the machine operator or notifications of machine
break downs with duration and cause for monitoring the machine availability.
Up to now paper forms were practised by using the classical OMR technique (optical mark reader).
This kind of data entering has a lot of disadvantages and is mostly out of use.

The advantages of paper forms

there is no need for expensive investments for operating data terminals at all workstations

in many cases there is no place to install terminals or industry PCs

paper form can be designed in any form depending on the Q-information and the personal qualification

to enter data on a paper form is much easier than to handle an operator terminal

the use of a paper form is free from descriptions

the paper form is a visual document for controlling the regular quality inspection

Possibilities of designing forms

all information for the operation will be added automatically and specifically to the working place (machine no., part no. of running plant order etc.)

fields for entering Q-data

bar coding, each field is filled out with one bar

marking with a cross;

entering numbers for counted failures; e.g. failures occuring during the day can first be counted by
drawing strokes and then after work entered as numbers

letters; you shouldnt use letters for information that have to be identified uniquely.
Mix ups may happen (I similar 1, 0 similar O, B similar 8 etc.)

text fields; a free area for hand written notes. This area is scanned an stored as BMP, JTI ect..
It makes sense to have these fields on the backside of the form. Any kind of interpretation is not possible

Scanning of forms

scanning of all collected forms with a batch job. The scanner is equipped with a feeder and eventually
able to scan front and backside in one step

analysing of each scanned form by a pattern recognition program

each data field is checked, whether the contents is correct (cross, only numerical, date etc.)

Each field will be analysed exactly

if the pattern recognition is somewhat ambiguous the program recommends the value which fits best
but the operator has to commit

if the program is not able to identify the hand written symbol (mostly the operator is in a similar situation),
he has to enter the correct figure

Initially the forms may be filled out too hasty. Show your operators the result and he will write better next time.
After a short training period the most forms will be read without any interruption.
Some problems may rise from dirty places.

Example inspection chart

focus of analysis is the causative process

each process has its own list of potential failures

if more than one process is running on a machine, the failures of all processes are regarded

With these information and further like form no. etc. the form can be printed and copied.

Storing Q-data

storing in an inspection order
the entered data dont differ from those that have been entered in normal masks, the complete evaluation is available

storing at once in an archive file via iQ-MESSDAT
there is no link to any inspection order. You may import the data into an inspection order and then evaluate them.

storing in iQ-GQI
any kind of data can be stored, changed and deleted. Evaluations can be done with marketable tools like Excel or Crystal.